Beer making machine with direct steam injection

ABSTRACT

A beer making system may use direct steam injection during wort manufacturing. Steam may be added directly to the wort, and may be part of a recirculating mash system. The steam may be the primary mechanism for adding heat to the system, and may eliminate many problems that often occur when using conventional heating systems. A water reservoir may feed a stream generator, which may inject steam into wort during mashing or boiling steps. A controller may monitor temperature and other parameters, and may calculate the dilution of wort based on the water added through the steam injection and allow a brewing system to compensate for said dilution and still produce desired results.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of and claims priority toand benefit of U.S. patent application Ser. No. 14/807,753 entitled“Beer Making Machine with Direct Steam Injection” filed 23 Jul. 2015,the entire contents of which are hereby expressly incorporated byreference for all it discloses and teaches.

BACKGROUND

Beer making has existed since before the days of Pharaoh. The beermaking process has been modified and improved upon over the ages. Thetypical beer making process today involves malting barley which preparesstarches for an enzymatic conversion of the starches to sugars in aprocess known as mashing, then boiling the sugars prior to adding yeastto ferment the sugars into alcohol. The liquid manufactured prior toadding yeast is known as beer wort.

The machinery for brewing beer may involve industrial sized systems thatmay process many thousands of gallons at a time, professional craft beerbrewing equipment which may be process much smaller batches, and homebrewing equipment which may process as little as a gallon in each batch.In each case, the basic brewing process may be the same.

SUMMARY

A beer making system may use direct steam injection during wortmanufacturing. Steam may be added directly to the wort, and may be partof a recirculating mash system. The steam may be the primary mechanismfor adding heat to the system, and may eliminate many problems thatoften occur when using conventional heating systems. A water reservoirmay feed a stream generator, which may inject steam into wort duringmashing or boiling steps. A controller may monitor temperature and otherparameters, and may calculate the dilution of wort based on the wateradded through the steam injection.

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used to limit the scope of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings,

FIG. 1 is a diagram illustration of an embodiment showing arecirculating mashing system with steam injection.

FIG. 2A is a diagram illustration of an embodiment showing a boilingsystem with steam injection in a recirculating system.

FIG. 2B is a diagram illustration of an embodiment showing a boilingsystem with direct steam injection.

FIG. 3 is a diagram illustration of an embodiment showing arecirculating system capable of mashing and boiling.

FIG. 4 is a diagram illustration of an embodiment showing a steaminjection system.

FIG. 5 is a flowchart illustration of an embodiment showing a method ofa heating control loop.

FIG. 6 is a flowchart illustration of an embodiment showing a method foradding water to adjust dilution using a steam injection system.

DETAILED DESCRIPTION

Beer Making Machine with Direct Steam Injection

A steam injector may create and inject steam into wort during mashing orboiling stages of beer making. The steam injector may convert water intosteam, then inject the steam directly into the fluid, thereby heatingthe fluid.

In many cases, the steam injector may use water that is separate fromthe wort. For example, a system may have a reservoir or other watersource from which steam may be generated. In such cases, the heatingmechanism used to add heat to the overall system may process only waterand may not be exposed to the sugars and other materials present in thewort.

Because wort may contain sugars and other materials, heating the wort toboiling often produces some unwanted characteristics, not the least ofwhich is the difficulty of cleaning a heating mechanism. For example,brew kettles that may be heated with direct flame may caramelize some ofthe sugars on the bottom of the kettle, resulting in some off flavorsbut also creating a difficult cleaning problem.

Other systems for heating during mashing or boiling may also causecleaning issues. Recirculating Infusion Mash Systems (RIMS) and HeatExchanger Recirculating Mash Systems (HERMS) are two conventionalsystems that recirculate mash liquid and apply heat to the liquid in arecirculating circuit. Such systems often build up sticky sugars andother materials in the heating section, resulting in a cleaning problem.

A steam generation and injection system may eliminate many cleaningproblems of a beer making system by eliminating contact between wort andrelatively high temperature heat sources. Such issues may be a problemin consumer-level devices as well as commercial systems.

A steam generator and injector may have a water source, such as areservoir, a pump to deliver and meter water to a heater which producessteam, and an injector mechanism to add the steam to wort. The systemmay include a temperature controller which may generate steam until adesired wort temperature is achieved.

A controller may also determine the amount of water added to a batch ofwort in the form of steam. Adding water in the form of steam may dilutethe wort. In some cases, a recipe may start with a reduced amount ofwater and may be designed to achieve a desired specific gravity byconsidering the amount of water added through the steam heating process.

In cases where the heating process may consume less water thananticipated, the controller may cause additional water to be addedthrough the steam generator system but without necessarily heating thewater to steam. Such a step may dilute the wort to a desired level,without unintentionally affecting the overall temperature of the wort

In the case where the heating process consumes much more water thananticipated, a system that uses only steam injection heating may have nomechanism to boil off or otherwise dilute the wort to a desired specificgravity. Because of this issue, many systems may pre-design recipesanticipating that the resulting wort may be diluted by adding water nearthe end of the heating process.

A beer making system may have a recirculating mashing or boiling systemthat may have a steam injection system. The machine may have a pump thatmay recirculate wort through a steam injector and return the heatedwort. In a mashing operation, such a system may recirculate the heatedwort to a grain bed during mashing and sparging operations. During aboiling operation, such a system may recirculate the heated wort back tovessel or reservoir for the boiling wort.

The term “boiling” step may refer to the portion of wort manufacturingwhere the wort is raised to a high temperature. Such a step may removeunwanted bacteria, stop the enzymatic reaction during mashing, sterilizethe wort, precipitate various proteins from the mashing process, extractvarious components from hops added during the boil step, and otherprocesses.

The “boiling” step as referred to in this specification and claims mayrefer to bringing wort to a high temperature, typically in excess of 190F, either with or without the physical boiling action. In someinstances, a rolling boil may be achieved, but in other instances, aphysical “boil” process may not be achieved. Such a “boil” step mayproduce many of the same desired outcomes, such as sterilization,isomerization of hops, stopping the enzymatic processes, and others,without the physical rolling boil.

Throughout this specification, like reference numbers signify the sameelements throughout the description of the figures.

When elements are referred to as being “connected” or “coupled,” theelements can be directly connected or coupled together or one or moreintervening elements may also be present. In contrast, when elements arereferred to as being “directly connected” or “directly coupled,” thereare no intervening elements present.

In the specification and claims, references to “a processor” includemultiple processors. In some cases, a process that may be performed by“a processor” may be actually performed by multiple processors on thesame device or on different devices. For the purposes of thisspecification and claims, any reference to “a processor” shall includemultiple processors, which may be on the same device or differentdevices, unless expressly specified otherwise.

The subject matter may be embodied as devices, systems, methods, and/orcomputer program products. Accordingly, some or all of the subjectmatter may be embodied in hardware and/or in software (includingfirmware, resident software, micro-code, state machines, gate arrays,etc.) Furthermore, the subject matter may take the form of a computerprogram product on a computer-usable or computer-readable storage mediumhaving computer-usable or computer-readable program code embodied in themedium for use by or in connection with an instruction execution system.In the context of this document, a computer-usable or computer-readablemedium may be any medium that can contain, store, communicate,propagate, or transport the program for use by or in connection with theinstruction execution system, apparatus, or device.

The computer-usable or computer-readable medium may be, for example butnot limited to, an electronic, magnetic, optical, electromagnetic,infrared, or semiconductor system, apparatus, device, or propagationmedium. By way of example, and not limitation, computer readable mediamay comprise computer storage media and communication media.

Computer storage media includes volatile and nonvolatile, removable andnon-removable media implemented in any method or technology for storageof information such as computer readable instructions, data structures,program modules or other data. Computer storage media includes, but isnot limited to, RAM, ROM, EEPROM, flash memory or other memorytechnology, CD-ROM, digital versatile disks (DVD) or other opticalstorage, magnetic cassettes, magnetic tape, magnetic disk storage orother magnetic storage devices, or any other medium which can be used tostore the desired information and which can accessed by an instructionexecution system. Note that the computer-usable or computer-readablemedium could be paper or another suitable medium upon which the programis printed, as the program can be electronically captured, via, forinstance, optical scanning of the paper or other medium, then compiled,interpreted, of otherwise processed in a suitable manner, if necessary,and then stored in a computer memory.

When the subject matter is embodied in the general context ofcomputer-executable instructions, the embodiment may comprise programmodules, executed by one or more systems, computers, or other devices.Generally, program modules include routines, programs, objects,components, data structures, etc. that perform particular tasks orimplement particular abstract data types. Typically, the functionalityof the program modules may be combined or distributed as desired invarious embodiments.

FIG. 1 is a diagram illustration of an embodiment 100 showing arecirculating brewing system with steam injection. Embodiment 100 is anexample of a mashing system that may be heated by injecting steam into arecirculating wort path.

By injecting steam directly into the wort, the heat contained in thesteam may be transferred into the wort. The recirculating system may mixand disperse the heated wort, thereby raising the temperature of thewort in a consistent manner.

The steam temperature may be any temperature above boiling. In somecases, steam temperature may be 220 F, 250 F, 300 F, or higher. Becausethe heat transferred is largely due to the phase change energy ratherthan the temperature change of the steam when injected, the temperaturecontrol of the steam need not be highly precise.

Embodiment 100 illustrates a recirculating mash system where a mash tun102 may contain a grain bed 104 located above a screen 106. An inlet 108to a recirculating pump 110 may draw liquid from the bottom of the mashtun 102 and pass the liquid past a steam injector 112 to an outlet 114.

The recirculating system of embodiment 100 is a simplified version of atypical system. In many cases, such a system may have a mechanism toheat the water prior to introducing the water to the grain bed 104. Sucha mechanism is not illustrated here.

A mashing system may use a grain bed 104 that may contain malted barleyand other grains that may have been crushed in a mill. A mashing processmay begin with water preheated to a specific temperature, thenintroducing the water to the grain bed. As the water flows through thegrain bed, the temperature may be raised or lowered according to aschedule. During the mashing process, various enzymes in the grains mayextract sugars from the grains, thereby producing wort.

In a typical mash schedule, the liquid may have a temperature from 130 Fto 170 F, although different mashing schedules may have temperaturesabove and below those temperatures.

A steam generator 116 may create steam from a water reservoir 118. Amore detailed description of a steam generator 116 may be found later inthis specification.

Some systems may have a programmable controller that may control therecirculating pump 110 and steam generator 116. Such a system maytypically operate the recirculating pump 110 continually during a mashcycle, and the steam generator 116 may add heat in response to atemperature input, adding steam when the temperature is below a desiredset point and not adding steam when the actual temperature is withinrange of the set point.

In many mashing schedules, the set point temperature may be variedthrough the mash process. Some mash schedules may additionally havetemperature ramps where the set point may increase or decrease over timeat a predefined function. The function may be a straight-line ramp,exponential curve, or other function.

FIGS. 2A and 2B are example configurations of a brewing system that usessteam injection during a boiling cycle for beer brewing. FIG. 2A mayillustrate embodiment 200 showing a recirculating system with steaminjection, while FIG. 2B may illustrate embodiment 202 showing directinjection of steam into a boil kettle.

Like with the mashing system of embodiment 100, steam may be a usefulheat source for a boiling operation. Traditional brewing systems mayachieve a rolling boil during the boiling cycle, while some systems mayonly achieve a temperature near the boiling temperature, typically 212degrees F.

The boiling cycle of beer making performs two functions. The firstfunction may be to stop the enzymatic operations of the mash cycle andthe second function may be to create bitterness, aroma and/or flavorsthrough interactions with hop organic matter including alpha and betaacids and oils. Other functions may occur as well during the boilingcycle, but many if not all the functions may occur without achieving anactive boil and by keeping the temperature of the wort below its normalboiling temperature.

Embodiment 200 illustrates a system where heat may be added throughsteam injection in a recirculating circuit. A boil kettle 204 maycontain wort 206. An inlet 208 may supply a recirculating pump 210,which may cause wort to pass past a steam injector 212 and to an outlet214 to be reintroduced to the boil kettle 204.

The steam injector 212 may emit steam generated by a steam generator216, which may generate steam from a water reservoir 218 or other watersource.

Embodiment 202 illustrates a system where heat may be added throughdirect steam injection into a boil kettle 220. In such a system, a boilkettle 220 may contain wort 222 that may be heated by a steam injector224 that may introduce steam directly into the wort 222. A steamgenerator 226 may supply the steam from a water reservoir 228.

FIG. 3 is a diagram illustration of an embodiment 300 showing amulti-stage beer making system with steam injection. Embodiment 300 mayillustrate a system that may use a single wort reservoir 302, and mayperform steps of mashing and boiling.

Embodiment 300 may use a recirculating circuit in which steam may beinjected for heating wort during various stages of beer wortmanufacture. The recirculating circuit may include an inlet 304, arecirculating pump 306, a steam injector 308, and a valve manifold 310.The valve manifold 310 may be switchable to a flow path 312 for grainmashing, a flow path 314 for a boil cycle, and a bypass flow path 316.

The bypass flow path 316 may be used to raise the temperature of theliquid in the wort reservoir 302. The steam injector 308 may heat thewater to a desired temperature through the bypass flow path 316. Thismay be used, for example, to heat water prior to starting a mash cycle.

A mash cycle may involve introducing the water into the grain steepingcontainer 318 and a grain bed 320 through flow path 312. During a mashcycle, the steam injector 308 may add heat to the recirculating liquidto maintain a desired temperature, as well as to raise the temperatureaccording to a temperature profile.

After completing a mash cycle, the valve manifold 310 may be changed topath 314, where wort may be passed through an adjunct steeping container322. The adjunct steeping container 322 may contain hops or otheradjuncts that may be introduced in the recirculating circuit during aboil cycle. The steam injector 308 may add heat to the recirculatingliquid to raise the temperature of the liquid to below, above or nearits boiling temperature. The adjunct steeping container 322 may havemultiple compartments, some or all of the compartments may be selectablethrough the valve manifold 310.

Steam to heat the liquid may be produced by a steam generator 324, whichmay use water from a water reservoir 326 or other water source.

The system of embodiment 300 is merely one more example of using steaminjection in a recirculating brewing system. In the various embodiments,a recirculating pump 306 may be illustrated as being upstream from thesteam injector 308. Other embodiments may have the steam generator 308upstream from the recirculating pump 306.

Some versions of a recirculating system may use the steam generator 324instead of in conjunction with a recirculation pump 206 to recirculateliquid through the system. Such a version may have a check valve locatedupstream from the steam generator, and the injected steam may force theliquid in the recirculating loop to be pushed vertically upwards andthrough the piping. Some such versions may use siphons or other fluidcircuit components to cause the fluid to move.

In the various examples of embodiments 100, 200, 202, and 300, a singlesteam generator system is shown. In some embodiments, multiple heatsources may be used. For example, a steam injection heating system maybe used in conjunction with an open flame or steam jacket apparatus. Theopen flame or steam jacket may be used to raise the temperature of theliquid in a vessel quickly, and the steam injection system may be usedto maintain fine control over the temperature.

Some embodiments may employ multiple steam injectors. An example mayinclude a recirculating system with steam injection as well as directsteam injection into a wort reservoir. In such a system, the directsteam injector may assist in raising the temperature of the liquid inthe reservoir with the recirculating system maintaining fine control asthe liquid temperature reaches the desired set point. Other systems mayhave two or more steam injectors in a single recirculating system.

FIG. 4 is a diagram illustration of an embodiment 400 showing a steamgenerator. The steam generator may be used to create steam from water,and the steam may be injected into wort to heat the wort during variousstages of wort manufacture.

The steam generator of embodiment 400 may have a water source 402, whichmay be a reservoir or a connection to another water source, such as abuilding's potable water supply. A pump 404 may control the amount ofwater pulled from the water source 402.

Some embodiments may have a check valve 406 between the pump 404 and aheater 408. The check valve 406 may prevent steam generated by theheater 408 from flowing backwards towards the water source 402. Such acheck valve 406 may be useful in situations where the pump 404 may notseal against backpressure, such as various types of so-called velocitypumps. Other pumps, such as positive displacement-type pumps, may haveintegral check valves such that a separate check valve 406 may beomitted.

The heater 408 may be an electrically operated heater that causes theliquid water to convert to steam. The steam may pass through a secondcheck valve 410 prior to exiting through a steam outlet 412.

The check valve 410 may prevent wort or other liquid being heated frombacking up into the heater 408. In some embodiments, the check valve 410may be located very near or integrally with the steam outlet 412.

A controller 414 may use inputs of a temperature measurement 416 and atemperature set point 418 to determine when and how to operate the pump404 and heater 408. In a simplified operation, the controller 414 mayoperate like a thermostat, where the controller 414 may cause steam tobe generated when the temperature measurement 416 is lower than thetemperature set point 418.

In many embodiments, the heater 408 may be kept at an operatingtemperature during normal operations. In such cases, operating the pump404 may cause water to be introduced into the heater 408 and steam maybe generated very quickly.

Some embodiments may use multiple stages of heating. For example, waterin a reservoir or water source 402 may be preheated and maintained at agiven temperature, and the preheated water may be introduced to theheater 408 to be converted to steam. In one example, a water reservoirmay contain water preheated to temperatures in the range of 120-170 F.By preheating the water, less energy may be consumed in the transitionto steam, which make such a system more responsive to generate steamquickly.

Some steam generators may use gravity to supply water rather than apump. One version of such a system may use a valve or other mechanism toregulate the water introduced into the heater. Another version of such asystem may use gravity to supply water, and may control the heatingelement to start and stop steam generation.

FIG. 5 is a flowchart illustration of an embodiment 500 showing asimplified example of a heating operation that may be performed by acontroller for a steam generator.

Other embodiments may use different sequencing, additional or fewersteps, and different nomenclature or terminology to accomplish similarfunctions. In some embodiments, various operations or set of operationsmay be performed in parallel with other operations, either in asynchronous or asynchronous manner. The steps selected here were chosento illustrate some principles of operations in a simplified form.

Embodiment 500 is a simplified example of a control loop that may adjusta temperature of a liquid by adding steam to raise the temperature. Thecontrol loop may have a duty cycle management function that may limitthe steam generated based on an operational duty cycle. The duty cyclemay be a restriction on the amount of steam that may be generated over aperiod of time, and limited duty cycles may be useful when full time of100% usage may cause overheating or other limitations.

A brewing step may begin in block 502. The brewing step may becontrolled by a second controller that may automate some or all of abrewing process. Such a controller may have a recipe from which variousprocess parameters, steps, and other information may be extracted. At aspecific brewing step, such a controller may transmit a targettemperature to a steam controller in block 504.

Prior to entering a control loop, the heating element that generatessteam may be turned on in block 503. Some hardware systems may have asteam heater that may maintain a constant temperature and steam may begenerated by introducing water into the heating element. In suchsystems, the heating element may be not be turned on and off frequently,and may generally be turned on and left on during an entire step of abrewing process.

A measurement may be made in block 506 for a liquid to be heated. If thetemperature is at or above the target temperature in block 508, theprocess may loop back to block 504 to determine if any changes have beenmade to the target temperature. If the measured temperature is below thetarget temperature in block 508, the system may be calling foradditional heat.

A duty cycle of the steam injection system may play a part in limitingthe amount of steam generated. In some systems, operating at 100% dutycycle may cause malfunctions, excessive electrical drain, excessiveheat, or other mechanical issues with the equipment. When a duty cycleis imposed on the system, if the duty cycle has been exceeded in block510, the control loop may return to block 504 until the duty cycle hasbeen satisfied.

In block 512, a check of the water supply may be made. When the waterlevel is low or water is otherwise not available, an alert may be sentin block 514 and no steam may be generated. Some systems may also shutoff a steam heating element under these circumstances as well.

The pump may be engaged in block 516 to cause water to generate steam.In the example of embodiment 500, the operations of block 516 may beperformed for a specific length of time, which may be a single second orhandful of seconds, for example. Other embodiments may turn on the pumpand allow the pump to operate continually while the heating loop cyclesmultiple times until conditions arrive where the pump may be turned off.

As the pump operates, a log may be made of the amount of steam or wateradded to the liquid being heated. Such a measurement may be used laterto adjust the concentration of liquid being heated.

FIG. 6 is a flowchart illustration of an embodiment 600 showing asimplified example of an operation to adjust the concentration of wortafter a brewing step may be completed.

Other embodiments may use different sequencing, additional or fewersteps, and different nomenclature or terminology to accomplish similarfunctions. In some embodiments, various operations or set of operationsmay be performed in parallel with other operations, either in asynchronous or asynchronous manner. The steps selected here were chosento illustrate some principles of operations in a simplified form.

As steam may be injected into a liquid, the dilution or concentration ofmaterials in the liquid may change because the water contained in thesteam becomes incorporated into the liquid. Many beer recipes aredesigned to have a specific concentration of sugars or other suspendedor dissolved components, and for steam injection heating, such recipesmay be designed to have a slightly higher concentration at thebeginning, with the expectation that the steam may dilute the liquid asheat is applied.

The amount of water added to the liquid through the steam injectionprocess may vary from one situation to another. The ambient temperature,humidity, initial temperature of the water, additives in the water,temperature of the heating element, or other factors may cause differentamounts of water to be added from one usage to another. Recognizing thissituation, some systems may make an adjustment to the dilution afterheating to achieve a desired concentration. Such systems may have arecipe that results in a more concentrated solution based on theestimated amount of steam

A brewing step may end in block 602. From a log of the amount of steaminjected, a total amount of water added through steam injection may bedetermined in block 604. An amount of additional water to be added maybe calculated in block 606 to achieve a desired dilution.

The heating element of a steam generator may be turned off in block 608and the steam generator pump may be operated in block 610 to addunheated water to the wort. The unheated water may dilute the wort to adesired level to match a recipe.

The foregoing description of the subject matter has been presented forpurposes of illustration and description. It is not intended to beexhaustive or to limit the subject matter to the precise form disclosed,and other modifications and variations may be possible in light of theabove teachings. The embodiment was chosen and described in order tobest explain the principles of the invention and its practicalapplication to thereby enable others skilled in the art to best utilizethe invention in various embodiments and various modifications as aresuited to the particular use contemplated. It is intended that theappended claims be construed to include other alternative embodimentsexcept insofar as limited by the prior art.

What is claimed is:
 1. A system comprising: a water input; a pump havingan electrical input; a heater; a steam injector, said steam injectorhaving a liquid connection configured to inject steam into a processedliquid; a connection from said steam injector to a reservoir thatcontains said processed liquid; plumbing connecting said water input,said pump, said heater, and said steam injector in sequence; acontroller having: a temperature sensor input; a temperature set pointinput for said processed liquid; and a pump output connected to saidelectrical input of said pump.
 2. The system of claim 1 furthercomprising a check valve.
 3. The system of claim 2, said check valvebeing located between said heater and said steam injector.
 4. The systemof claim 2, said check valve being located between said pump and saidheater.
 5. The system of claim 1, said water source being a waterreservoir.
 6. The system of claim 1, said pump being one of a groupcomposed of: a peristaltic pump; a diaphragm pump; and a positivedisplacement pump.
 7. A controller comprising: a set point input for aprocessed liquid stored in a reservoir; a temperature measurement input;a pump output; a heater output; said controller being configured to:determine a target temperature from said set point input; determine acurrent temperature of a processed liquid from said temperaturemeasurement input; determine that said current temperature is below saidtarget temperature; and activate said pump output and said heater outputto cause steam to be generated and injected into said processed liquid.8. The controller of claim 7 being further configured to: determine anamount of water added to said processed liquid over a period of time,said amount of water being added primarily as steam.
 9. The controllerof claim 8 being further configured to: determine a second amount ofwater to be added as liquid; and activate said pump output to cause saidwater to be added as liquid to said processed liquid.